Steam system control



3 Sheets-.Sheet 1 O. A. HUNT ETAL STEAM SYSTEM CONTROL v -July 18, 1950 Filed Feb. 28,V 14949 July 18, 1950 Filed Feb. 28, 1949 o. A. HUNT ETAL STEAM SYSTEM CONTROL v3, Sheets-Sheet 2 FIG-2 July 18, 1950 o. A. HUNT Erm.

STEAM SYSTEM CONTROL Filed Feb. 28, 1949 5 sheets-sheet s wwwa@ Patented July 18, 1950 i l STEAM SYSTEM CONTROL Orville A. Hunt and Lonin Tiller, Chicago, Ill.,

,assignors, by mesne assignments, to Reconstruction Finance Corporation, Chicago, Ill., a corporation of the United States Application February 28, 1949, Serial No. 78,842

21 Claims. (Cl. 237-9) The present application isa continuation-in- Y' part of our previous application S. N. 762,628, entitled Steam System, filed July 22, 1947, and

our previous application S. N. 764,454, entitled Steam System Control, filed July 29, 1947, both of which are abandoned. Both of these previous disclosures are incorporated in the present disclosure by reference insofar as consistent therewith.

Other copending applications disclosing the subject matter related hereto are: S. N. 78,605, filed February 26, 1949; S. N. 78,843, led February 28, 1949; S. N. 78,604, led February 26, 1949; S. N. 80,802, filed February 28, 1949; and S. N. 777,894, filed October 4, 1947.

A steam system of the type here under consideration may be termed a clear channel system, meaning that a clear channel (no traps) exists from the boiler through the equipment to the return line. Such a clear channel makes the whole system responsive in the sense that a drop in pressure at the end of the return line causes an immediate velocity response throughout all the equipment. This fact is important because it makes possible velocity control for the whole system at a single point at the end of the return line.

The general object of the invention is to control the iiow velocity throughout the steam system with high eiciency, to effect certain economies in the handling of condensate and in the preheating and deaerating of make-up water, and to accomplish these purposes by means of a compact automatic master control that may be manufactured as a self-contained packaged unit for incorporation in existing steam systems.

It is old to create such a pressure differential and consequent velocity response solely by opening a valve at the end of the return line, as disclosed in the above-mentioned patent, the released fiuid being utilized to preheat and deaerate make-up water for the boiler. But while such a valve` arrangement used alone is highly eiective and has' been commercially successful, nevertheless in some situations it presents certain problems in economy and efliciency, which problems, we find, can be solved byV add-ing other ways of promoting velocity and of utilizing steam at the return end oi the system.

The broad object of the present invention is to provide such solutions by certain actions at the end of the return line. One such action is the removal of condensate under pressure from the return line above the release valve for direct return to the boiler. This action of course has a flow-promoting effect on the responsive clearchannel system. Another action is the condensing of steam in the return line above the release valve. This action, too, supplements the owpromoting effect of the release valve and in addition consumes steam in the return line. Other actions include cooling actions taking place in a receiver at the end of the return line, the release valve being adapted to open in response to such cooling. These various actions are combined with l the action of the release valve in various ways in various practices of the invention.

Some of the objects of the invention are largely attained by using a release valve at the end of the ,return line that responds to the heating and coolpositioned .downstream from the valve tobe heated by the return-line fluid discharged from the valve. y

If the thermostat that controls the. release valve is positioned upstream from the valve, it is adapted to cause opening action of the valve in response to rising temperature in the return linev and closing action in response to dropping temperature. On the other hand, if the controlling thermostat is positioned downstream from the release valve, it is adapted to cause closing action of the valve in response to temperature rise and opening action in response to temperature. drop.

In both cases the eiect' is to cause the valve to operate automatically for maintaining a pressure drop across the system'suficient for whatever cause operation of the release valve at some temperature below the temperature of the steam supply ofthe system and therefore causes and predetermines flow of va vdesired velocity from the steam supply through the equipment back to the boiler. The result is controlled operation of the whole steam system with sustained high level heat output to the material in process.

An important advantage and object of our invention is the combining of the advantages of an open steam system" with the advantages of a closed steam system. The release valve at the end of our steam system can set up a high-pressure differential across the system for flow promotion in the same manner as an open steam system; and on the other hand, the removal of the condensate from the system yupstream from the valve makes it possible to keep the condensate under pressure and return the condensate to the boiler at a high temperature characteristic of closed steam systems.

A further object of the preferred practice of the invention is not only to promote velocity in the system by pressure drop at the end of the return line, but also to deliver the make-up water to the boiler at a higher temperature than possible in any conventional steam system. This Vdual object is accomplished by transferring heat from the return line to the make-'up water as themake-up water travels from the usual feed pump to the boiler. Thus the make-up watercauses condensation in the return line to promote flow velocity in the system and atthe same time is itself raised to a high temperature on the order of 300 F. It is possible to heat the make-up water to this high temperature and to do so without creating any pumping problem because the additional heating occurs on the discharge side of the feed pump where the water is under high pressure.

The above and other objects and advantages of the invention will be apparent from the following description taken with the accompanying drawings. In the drawings, which are to be considered as merely illustrative:

Fig. 1 is a diagram of a representative steam system incorporating the new control unit;

Fig. 2 is a fragmentary view of a restriction that may be substituted in Fig. 1;

Fig. 3 is a fragmentary diagrammatic view showing a modification of the arrangement shown in Fig. 1;

Fig. 4 is a view similar to Fig. 3 showing another modification of the invention;

Fig. 5 is a diagram showing how a timer can be used in Fig. 1; and

Fig. 6 is a diagram similar to Fig. 1 with the Q III. In some practices of the invention the tank i0 will be maintained above atmospheric pressure but, of course, below the pressure of the return line Il. K

In rvthe steam system shown in Fig. 1, steam from a boiler'23 is supplied ythrough a header 2i to a plurality oi' equipment heatexchangers or steam-using devices 2|. Buch devices may be, for example. the various machines in a laundry or the drying equipment used in paper manufacture. plastics,l etc. Return pipes 21 from the various pieces of equipment connect with the previously mentioned return line Il.

Each of the return pipes 21 is provided with a suitablerestriction such as an adjustable valve 28`instead of a conventional steam trap. Other types of restrictions may be employed. For example, in some practices of the invention small diameter pipes are placed in the return lines as indicated at 30 in Fig. 2. It is contemplated that in all instances where orices or restrictions are used instead of traps, there will be open communication from the return line il back through the various pieces of equipment 26' to the steam supply so that the lowering of pressure in the return line Il will cause velocity response in each of the steam-using devices.

Preferably, condensate is continuously or continually` removed from the return line I8 and the thermostatic valve downstream from the release I valve that it controls.

Fig. l shows diagrammatically the principal elements of a typical steam system under the control of the particular form of the new master control unit that has the thermostat upstream from the release valve that it controls.

The control unit includes an upright tank or receiver i0 and various other elements to be described, all of which are by preference enclosed in a housing or casing represented by the rectangle ii shown in broken lines. In other words, the rectangle i i represents a self-contained unit.

Fig. 1 shows ve important pipes connected to the master control unit: a pipe i5 for supplying new water to the unit; a pipe i6 connected to the discharge side of the usual boiler feed pump; a pipe I1 which is the boiler feed line for supplying water to the boiler; the return line I8 of the steam system, and, at a lower level, a pipe 20 to the intake side of the boiler feed pump. If desired, an additional vent pipe (not shown) may return line is suitably designed to facilitate such removal. For example, the return line may be arranged to cause the condensate to gravitate to a point for collection and removal and in addition may be enlarged in cross section near the collection point -to favor separation of the condensate from steam in the return line.

In the particular arrangement shown in Fig. 1 by way 0f example, the return line il includes as a part thereof a steam separator 3i which preferably, but not necessarily. also serves as a heat exchanger for using the returns of the system to heat new make-up water. If desired, suitable baiiies 32 may be provided in the separator 3| to facilitate separation of the steam and condensate.

In the preferred practice of the invention condensate that is separated from the steam gravi tates through a pipe 33 to the intake side of a condensate pump 35 that is included in the working parts of the master control unit. The pump 35 discharges the condensate upward through a pipe 38. It is contemplated that the pump 3l will operate continuously but in some practices of the invention the pump may operate only periodically, for example. in response to fall in the water level in the iler 2l.'

A valve 31 is provided in the pipe 33 to cut the heat exchanger oifrom the pump if and when desired. When the valve 31 is closed all of the condensate and steam that reaches the separator 3i must flow from the separator through a pipe 38. The pipe 33 conducts fluid from the return line i8 into the receiver tank I0 and is in effect a continuation of the return line I8.

The pipe 3l leads to a two-stage combined heater and mixer 40 which in turn communicates with a spray head 4i having numerous downwardly directed spray ports. Flow through the pipe 33 into the tank Il is controlled by a ther mostatic release valve 42 having a thermostat bulb 43 extending into the return line il upstream from the separator 3i. Fig. 1 shows the thermostat bulb I3 extending into a special fitting I4 that is included in the return line i8. The thermostatic control is such that valve 42 opens be connected to the vent opening'zi of the tank 75 in response to increase in temperature of the thermostat bulb. and closes in response to-del creasing temperature of the bulb. The critical temperature at which the valve opens and closes may be varied by virtue of a manual adjustment 45 on the thermostatic valve 42.

The steam or steam mixed with some condensate that ilows through the pipe 30 and the valve 4-2 enters a central upright passage 46 in the twostage heater 40 and divides, -one portion nowing into an upper jet 41 for the first-stage heating of new water, and the other portion flowing into a lower jet 48 for the second-stage heating. The upper jet 41 is directed into a venturi throat Il and the lower jet 40 is directed into a corresponding venturi throat 5|, each jet and throat forming a low pressure space for .the introduction of uid.

New water for the steam system from the previously mentioned supply pipe I5 passes through a solenoid valve 52 and through a vent condenser .53 to a pipe 55 that enters the two-stage heater 4l in the low-pressure space between the nrst jet 41 and venturi throat 50. The valve 52 may be in the pipe 55 instead of in the pipe I5, if desired. The resulting mixture from the venturi throat 50 flows through a lateral connection passage 54 into the low-pressure space between the second jet 43 and the second venturi throat 5|, where it is joined by the second portion of hot fluid from the pipe 33. From the two-stage heater 40 the iluidows into the spray head 4|. The new water is not only heated by thev addition of the steam or condensate from the return line but is'also under considerable pressure in the spray head 4|. and is. discharged downwardly through the spray ports with considerable violence.

-When the Water at high pressure and heated substantially above 212 F. is released in finely dividedparticles from the spray head 4| vinto the interior of the tank i0, the water particles are shattered by ashing action and the noncondensible gases are effectively released from the water to escape upwardly through the vent opening 2|. The vent condenser 53 not only reclaims heat from the escaping gases but also condenses any vapors that tend to escape with the gases, the recovered condensate dripping to the bottom oi the tank.

It is contemplated that the spray capacity of the spray head 4| will be so limited relative to the input of iluid that the pressure in the spray head will rise above the pressure prevailing in the tank I when the thermostatic valve 42 is open. Under such conditions, the pressure in the spray head may go substantially above the tank pressure. It is further contemplated that the extent to which pressure will rise in the spray head under given conditions may be varied either by varying the number of spray openings or changing the size of the spray openings.

The tank I0 contains in its lower portion a reserve body 55 of the deaerated make-up water supplied by the above-described spray action.

`When the level of this body drops, a `suitable 6 If the level of the water body 55 rises too high, it overilows through an overflow pipe 53. The

. overilow pipe 62 is formed into a loop with a submerged end to prevent excessive escape of vapor through the pipe, but the loop is provided with a small vent aperture to prevent siphon action. When desired, the tank may be drained by opening a drain valve 65.

The deaerated make-up water at nearly 212 F. temperature is taken from the tank I0 through the previously mentioned pipe to the intake side of the usual boiler feed pump 61 and is discharged by the pump into the previously mentioned pipe I6 that is connected to the control unit at the top. The pipe I6 is connected to`the inlet end of a heat-exchange coil 63 in the previously mentioned steam separator 3|. The outlet end of this coil 60 is joined to the previously mentioned pipe 36 from the condensate pump 35 to supply the previously mentioned boiler feed line-I1 as shown in Fig. 1. It is apparent that .-the pressure on the outlet side of the condensate pump 35 is greater than the prevailing pressure in the return line I3.

When make-up water is pumped through Lthe coil 68 by the boiler feed pump 61, the make-up water being substantially below the temperature of the interior of the separator 3| causes steam in the separator to condense. This condensing action creates velocity throughout the system by the contraction involved in the change of state to the previously mentioned pipe I6. The pipe I6, as previously mentioned, delivers make-up water to the coil 68 in the separator 3|. The pipe |03 diverts a portion of the make-up water to a spray head |04 inside the separator. Preferably, valves |05 and |06 are provided for adjustment to vary the proportion of make-up water that is diverted to the spray head |04.

The feed pump 61 may be controlled in a well known manner by means responsive to changes in the water level in the boiler 23 or in s'ome practices of the invention may be manually adjusted to run continuously at approximately the rate required to keep the'boiler level constant. In either event, the iloat 6| in the master control tank |0 will drop periodically to cause new water to be supplied tothe system in accord withthe boiler demand.

For proper performance of the described deaeration operation fluid must be released from the return line I8 into the master control tank I0 simultaneously with the flow of water into the tank from the pipe |5. To this end, a pipe 10 from the separator 3| communicates with the upper end of the passage 46 in the two-stage heater 40, in one practice of the invention as shown in Fig. 1. Flow through this second release pipe I0 is controlled by a solenoid steam valve 1|, which valve is connected in parallel with the previously mentioned solenoid valve 52 by a pair of wires 72. Whenever the solenoid valve 52 for water flow opens in response to lowering of the oat 56, the solenoid valve 1| for steam flow opens at the same time.

Operation o! the :team system shown infin. 1

'lhemannerintlrhichthedescribedsteam'system operates and is controlled by the described` communication through the system. In this method of operation. the ilow velocity is substantially higher than the overall or average velocity in a conventional trap system and the small proportion of steam that is continuously passing through the restrictions 28 eilectively carries the condensate out of the steam chests along with non-condensible gases. The drop in pressure c auses a small portion of the condensate vto ilash into steam thereby slightly increasing the steam content of the iluid mixture that reaches the combined heat exchanger and separator 3l. At the master control unit four major causes are in effect for sustaining ilow velocity throughout the steam system. In the first place. the continuous removal of condensate by the pump 35 from the lower end ofthe separator 3| creates ilow in the return line. In the second place, the condensing of steam in the separator 3| by the coolingei'lect of the water coil Il and/or the cooling eilect of water introduced by the spray head M4, serves to promote ilow by contraction of the fluid mixture at the end of the return line. In the third place, the release of steam or steam mixed with condensate, by opening of the thermostatic valve `42 causes flow throughout the system. And, in the fourth place, the release of steam from the return line by opening of the solenoid steam valve 1i likewise causes flow throughout the system.

A special advantage of pumping feed water through the heat exchanger coil i8 is that the water in the coil il is under high pressure and is therefore capable of absorbing more B. t. u.s y

from the return line than would otherwise be possible. This arrangement which raises the steam-condensing capacity of a given quantity of the make-up water to the maximum is especially valuable in a steam system having a relatively low make-up water demand.

Although opening the thermostatic valve 42 to create velocity may tend to lower the pressure of the condensate delivered to the condensate pump 35, the valve opens only intermittently so that such tendency to drop pressure c'an occur only intermittently.

The adjustment 45 of the thermostatic valve 42 is at a temperature value suillciently below the temperature prevailing in the steam header 25 to insure any desired minimum velocity of ilow through the system. In a laundry installation,

' for example, where the boiler supplies steam at asuma "8 Whenboththethermostaticvalveandtho `solenoidvalvellareclosed,theoperationottbe a constant gauge pressure of 100 pounds per square inch, the temperature prevailing in the steam header will be approximately 337 F. In.

perature in the return une wm enmb above 331 F. whereupon the heating oi the thermostat bulb 43 will automatically cause the thermostatic valve 42 to open for release of steam from the return line. 42 opens the temperature in the return line goes down and the thermostatic valve 42 automatically closes. Thus the thermostatic valve 42 automatically maintains any desired pressure drop between the boiler and the return end oi the system.

Whenever new water is demanded by the system, the oat 56 drops to cause energization o! the solenoid valve 52 for introducing new water. and the oat also causes simultaneous energias.- tion of the solenoid valve 'Ilv for concurrent now of steam into the two-stage heater 4I. Ordinarily both the thermostatic valve 42 and the solenoid valve Il cannot stay open simultaneously, because under such conditions the temperature in the return line I8 necessarily drops below the temperature setting of the thermostat control thereby causing the thermostatic valve 42 to remain closed. Consequently, whenever the master control unit takes in new water. steam is released from the return line of the system only through the pipe 'Il under control of the solenoid steam valve 1I. There would be no particular harm, however. in both steam valves 42 and Il being open at one time.

The thermostat valve 42 may completely close or only nearly close in response to dropping temperature, and the valve may be either a quickacting valve or a slow-acting valve. The solenoid valve 1i may also completely close or only nearly close when the control circuit Ienergized by the mercury switch 5l is de-energized.

In some practices of the invention both the solenoid valves 52 and Il will be operated intermittently by a suitable timer whenever the mercury switch 54 is closed', as taught in our previously mentioned copending application. Fig. 5 shows such a timer 13, which timer, for example, may be adapted to divide a thirty-second interval of time into an open valve period and a closed valve period in any proportion desired. For instance, the timer may be adjusted for repeated cycles of 10 seconds of ow followed by 20 seconds of no ilow through both valves.

Modifications of the arrangement shown in Fig. 1

the pipe Sl-being considered as a part of the` return line Il. For this Duri-*05e the pipe Il is provided with a special fitting 'I5 to receive the thermostat bulb 43.

Whenever the thermostatic valve In Fig. 4 the thermostat bulb I3 is positioned inside the separator 3|. may be placed in any location inside the steam separator but is shown in the drawing in a position just below one of the separator baiiies 32. Fig. 4 also illustrates how a trap 16 may be used instead of the pump 35 to remove condensate from the return line. condensate drains into the trap and is periodically discharged by the trap ior disposal or for return to the boiler as may be desired.

The temperature adjustment of the thermostatic valve 42 in the arrangement shown in Figs. 3 and twill be close to the adjustment employed in Fig. l. In any given installation, the temperature adjustment of the thermostatic valve will depend in part on the amount of make-up water per hour required by the system. In each instance, however, the proper adjustment of the thermostatic valve 42 for a high rate of heat output to the material in process may be readily ascertained by trial and error.

in the forms of the invention described to this point, care is taken that the thermostat bulb be acted upon by substantially the temperature of steam at whatever pressure prevails in the return line. If the presence `of non-condena; sible gases is at a minimum the temperature acting on the thermostat will be very close to the steam temperature corresponding to the return line pressure. lf considerable non-condensible gas is in the steam of a trap system to which this invention is applied, the temperature of the vapor in the return line will be depressed and the thermostatic control may be adjusted to compensate ior the lower temperature.

One thing that should be avoided is the flooding or submersion oi the thermostat bulb by stagnant condensate at a temperature below the settingy of the thermostatic valve. If the return lines are short or if the return velocity is high so that condensate therein is always close to the theoretical temperature of steam at the return line pressure, there may be no need for removing condensate from the return line independently of the thermostatic valve. There is less need in an orice system than in a, trap system.

lt may be readily understood then that the arrangement shown in Fig. l may be operated with the valve 3i closed and the pump 35 idle. In fact, this arrangement is especially favorable for such operation because when valve 31 is closed, the separator ti provides a temporary storage space downstream from the thermostat bulb for the accumulation of condensate. The thermostatic valve would open often enough for flushing action on the storage space to keep the accumulated condensate from rising to the level of the thermostat bulb.

The form of the invention .show'n'z'n Fig. 6

The purpose of Fig. 6 is to illustrate those practices of our invention in which the thermostat that controls the release valve at the end of the return line is positioned downstream from the valve to be heated by the fluid from the return line that is discharged by the valve. The major portion of the structure shown in Fig. 6 is similar to the structure shown in Fig. 1 as indicated by the use of corresponding numerals to indicate corresponding parts. The tank I instead of being at substantially atmospheric pressure is preferably maintained at a few pounds above atmospheric pressure, say, lbs. gauge, so that the temperature inside the tank will readily The thermostat bulb` at a slightly open position sufficient to maintain pressure in the tank on the order of, say 3 or 4 lbs. gauge, and the relief alve i0! may Ibe set to open say, at 8 or 10 lbs. pressure.

To maintain pressure in the tank i0 it is necessary to control the release of iluid through the overflow pipe t3.v Forthis purpose-Fig. 6 shows the overflow pipe 63' normally closed by a oat valve 64. Whenever make-up water rises high enough to open the float valve 5d the valve opens automatically to release overflow to the drain.

It will be noted that certain parts shown in- Fig. 1 are omitted in Fig. 6 including the pipe "l0, solenoid valve il, and the wires l2. The thermostat t3 of the valve 42 is shown positioned in the two-stage combined heater and mixer dit iear the outlet thereof adjacent the spray head It is contemplated that the discharge capacity of the spray head di will always be so limited relative to the input of iluid that the pressure in the spray head will rise substantially above the pressure prevailing in the tank i!) when the thermostatic valve 42 is open.

The thermostat arrangement is such that the valve l2 opens in response to decrease in temperature of the thermostat bulb t3 and closes in response to increase in temperature of the bulb. The critical temperature at which the valve opens and closes may be varied b'y the manual adjustment t5 and is set at some temperature above the temperature prevailing in the tank it. Thus the tank provides an environment for the thermostat bulb that tends to cool the bulb below its critical temperature when the spray head di is not in operation.

The manner in which the steam system shown. inl Fig. Goperates may be readily understood.

At the master control unit four major causes are in effect for sustaining now velocity throughout the steam system. In the rst place, the continuous removal of condensate by the pump td from the lower end of the separator 3i creates flow in the return line. In the second place, the condensing of steam in the separator iti by the cooling effect of the iwater coil 58 and/or by the cooling eiect of water introduced by the spray head H04 serve to promote ow by contraction of the fluid mixture at the end of the return line.

In the third place, the release of steam by opening of the thermostatic valve d2 causes ow throughout the system; and in the fourth place, the cooling effect of new make-up water ilowing through the vent condenser 53 reduces the temperature and pressure in the tank iii, thereby tending to cool the thermostat t3 for opening action of the thermostatic valve t2.

The adjustment d'5 of the thermostatic valve l2 is high enough to make the valve open in an intermittent manner thereby to cause pulsating flow throughout the system. In a steam system having approximately lbs. per square inch gauge pressure in the steam header 25, the setting of the thermostat valve may be, for example, about 230 F'. Since the master control tank is at atmospheric pressure, the tank interior cannot rise above 212 F. so the environment of the spray header 4l tends to cool the thermostat bulb below 230 F. thereby to cause the thermo- 11 stat valve 42 to open. When the valve 42 opens, however, the thermostat bulb is again heated above its critical temperature of 230 F. by the fluid released from the separator 3| thereby causing the thermostatic valve to close.

Since atemperature of 230 F. cannot be attained in the spray head 4I at atmospheric pressure, the initial ow of steam from the valve or the initial formation of steam by flash action vfrom condensate released through the valve does not have a temperature above 212 F. As soon as the restrictive action of the spray openings is effective to cause rising back pressure in the spray header, however, the temperature rises correspondingly and soon climbs above the critical temperature 230 F. It is apparent then, that the iiow passage from the thermostat valve 42 to the spray openings comprising the twostage heater 40 and the spray head 4l functions as a pressure accumulation space to make possible the relatively high temperature required for the purpose of valve control as well as for the purpose of deaerating the make-up water.

By virtue of the described cycle of alternate heating and cooling, the valve 42 opens intermittently in an automatic manner to maintain a desired minimum average flow velocity in the system during periods when no new make-up water is flowing. Whenever new make-up water is required, and the float 56 lowers to open the water valve 52, the thermostat bulb 43 is immediately cooled below its critical temperature. In the usual method of operation, the flow of new water is adequate to keep the thermostat valve 42 open in opposition to the heating effect of the fluid released by the valve, so that the thermostaticvalve stays open as long as the ow of new Water continues.

The valve 42 may completely close or only nearly close in response to rising temperature, and the valve may be either a quick-acting valve or a slow-acting valve. If a slow-acting valve is used. it will tend to stay open at an equilibrium position in the absence of water flow and will merely open wider in response to new water. In such instances, the pulsations in the system are governed primarily by the periods of water flow. Since every steam system has losses, however, which must be made up by new water, the new water demand can be relied upon to continually cause opening action of the valve 42 to create pulsations.

Since the master control responds to demand for new water at the boiler end of the system and in doing so speeds up velocity at the return end of the system, the unit may be said to tie the two ends of the system together functionally. The result is a closed chain of causes in which the demand of the boiler for a pound of water to replace a pound of steam consumed in the system causes enough velocity to be created to sweep out the resulting condensate from the steam chests in the system.

When the load on the steam system is steady the master control unit functions as automatic means to keep the overall or average velocity of the pulsating flow at a substantially constant level. Under constant operating conditions, with the average velocity level of the pulsating flow substantially constant, the boiler demand for new water will be met by a substantially constant ratio of new water to condensate. Under such circumstances if velocity were to tend to lag, there would be an immediate deficit in condensate returned and the demand for make-up water rial in process.

would temporarily increase. Such increase in the demand for make-up water would, however, act on the thermostat bulb 42 to increase velocity. Thus, any tendency for velocity to drop would be automatically corrected. In like manner any tendency for velocity to speed up excessively, would be automatically corrected by reducing the demand for make-up water and thereby reducing the quantity of fluid released by the valve 42.

Since changes in the load on the steam system cause corresponding changes in the demand for new water by the boiler with corresponding,

changes in the quantity-of make-up water required in a unit of time, it is apparent that the average or overall velocity of the system also shifts up and down automatically with changes in the load on the system.

Each time the valve 42 opens, it causes two things to happen. It causes a pressure pulsation or slight pressure drop in every steam chest in the system, and it causes velocity in the whole system to speed up. In other words, each opening movement ofthe valve 42 causes a. pressure pulsation in each piece of equipment and at the same time causes a strong surge of flow from the equipment through the return line of the system. The pressure pulsations attack the noncondensible gas films in the steam chests by causing a flashing action because each time the pressure drops slightly, a portion of every particle of water in the steam chests flashes into steam, There are countless water particles in and near the gas films and at 100 lbs. pressure per square inch the condensate that ashes into steam increases in volume over 240 times. As a result, each particle of water becomes an explosive center of turbulence to disrupt the gas films and to promote heat transfer to the mate- The gases torn away from the gas films are quickly picked up by the velocity surges and swept into and through the return line of the system. The velocity surges also sweep condensate out of the steam chests continuously and keep the condensate films exceedingly thin.

Tuning the unit to suit a particular steam system A feature of the invention is that it incorporates a number of elements that may be changed or adjusted to cause the master control unit to match precisely the requirements of any steam system within a very wide range. As a result. the control unit is extremely exible and is not only readily adaptable to the requirements of any particular system but is also adaptableto changes in a steam system such as the addition of new heating equipment. In the arrangement shown in Fig. 6, for example. any number of the following adjustments may be made to vary the operation and control characteristics of the unit:

l. The temperature adjustment 45 of the thermostatic valve 42 may be varied.

2. The rate of supply of the new water may be varied to change the cooling effect of the new water on the bulb 43. For example. the oat valve 52 may be restricted or limited in its opening action to any degree desired.

3. The closing action of the thermostatic valve 42, as well as the opening action, may be limited to any degreev desired.

4. The discharge capacity of the spray head 4I may be varied to vary the manner and degree of pressure rise in the spray head. To this end the spray openings may be varied in number or varied in size.

5. The pressure in the master control tank Il 13 may be raised or lowered'to increase or decrease the prevailing temperature in the tank.

The term "steam supply in the claims is to be understood as broad enough to `cover exhaust steam supplied by an engine or other source.

Our description in detail of selected practices of the invention for the purpose of disclosure and to illustrate the principles involved will suggest to those skilled in the art various changes and substitutions under our basic concept. We reserve the right to all such departures from our disclosure that fall within the scope of our appended claims.

We claim as our invention:

i. In a steam system having a boiler, at least one steam-using device connected to the boiler, and a return line connecting the steam-using device to the boiler and closed to the outer atmosphere, said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of a condensate pump in the return line for returning condensate to said 4boiler under pressure, said pump having its intake port in direct communication with said return line to promote flow of steam through the steam-using device, a valve to release iiuids from said return line into a region of substantially lower pressure than the return line to set up a pressure differential across the system for additional promotion of flow in the steam system, and a thermostat controlling said valve, said thermostat being positioned for rise in temperature by heat supplied by said return line.

2. lin a steam system having a boiler, at least one steam-using device connected to the boiler, and a return line connecting the steam-using device to the boiler and closed to the outer atmosphere, said device and return line forming a clear channel from said boiler for now-promoting pressure communication through the system, the combination therewith of: a valve to release huid from said return line into a region of substantially lower pressure than the return line to set up a pressure differential across the system for promoting flow of steam through the steamusing device, a thermostat controlling said valve, said thermostat being positioned for rise in temperature by heat supplied by said return line, and means operatively connected with the return line to bring cooling fluid into heat-exchange relation with the contents of said return line for causing condensation of steam therein to create a further pressure differential for further promotion of flow in the system.

3. In a steam system having a boiler, at least one steam-using device connected to the boiler, and a return line connecting the steam-using device to the boiler and closed to the outer atmosphere, said device and return line forming a clear channel from said boiler for ilow-promoting'plessure communication through the system, the combination therewith oi: means operatively connected with the return line to bring cooling fluid into heat-exchange relation with the contents of said return line for causing condensation of steam therein to set up a pressure differential across the system for promotion of ilow of steam through the steam-using device, -a condensate pump in the return line for returning condensate to said boiler, said condensate pump having its intake port in direct communication with said return line to remove condensate therefrom for further promotion of flow in the system, a valve to release iluid from said return line into a region of substantlally lower pressure than the return line to set up a still further pressure diil'erentlal across the system for still further promotion of iiow ln the steam system, and a thermostat controlling said valve, said thermostat being positioned for rise in temperature by heat supplied by said return line.

4. In a steam system having a boiler, at least one steam-using device, and a return line, said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of: a condensate pump having its intake port connected with said return line to promote Iiow in the system Vand having its discharge port under higher pressure than'the return line, a valve to release iiuid from said return line for further promotion of flow in the steam system, and a thermostat operatively connected to said valve for opening action of the valve in response to temperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with fluid in said return line upsteam from said valve, said temperature level being below the temperature of said steam supply.

5. In a steam system having a boiler, at least one steam-using device connected to the boiler, and a return line connecting the steam-using device to the boiler and closed to the outer atmosphere, said device and return line forming a clear channel from said boiler for now-promoting pressure communication through the system, the combination therewith of: a condensate pump in the return line having its intake port directly connected with said return line to promote flow of steam through the steam-using device and having its discharge port under higher pressure than the return line, a valve to release iiuid from said return line for further promotion of flow in the steam system, and a thermostat operatively connected to said valve for opening action of the valve in response to Atemperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with the fluid discharge from said valve for rise in temperature by heat supplied by said return line.

6. In a steam system having a boiler, at least one steam-using device, and a return line, said device and return line forming a clear channel from said boiler for How-promoting pressure communication through the system, the combination therewith of: a heat exchanger included in said return line having a passage for heating water, a valve to release 'fluid from said return line to promote flow in the system, a thermostat operatively connected with said valve for opening action of the valve in response to temperatures above a given level and closing action in response to temperatures below said level, said level being lower than the temperature of the steam supply, saidlthermostat being positioned for rise in temperature by heat supplied by said return line, a boiler feed line under pressure higher than the pressure in said return line, said boiler feed line including said passage in the heat exchanger to cause condensation in said return line for further promotion of flow in the system, and a pump having its intake side connected with said return line to continually remove condensate therefrom, said pump having its discharge side connected with said boiler feed line.

'7. In a steam system, a combination as set forth in claim 6, in which said thermostat is in l heat-exchange relation with the fluid discharge from said valve for rise in temperature by heat supplied by said return line.

8. In a steam system having a boiler, at least one steam-using device,\and a return line, said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of: a separator included in said return line, a valve to release fluid from said separator to promote flow in the steam system, a thermostat operatively connected to said valve for opening action of the valve in response to temperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with returns from the system upstream from said valve, and a condensate return pump having its intake side connected with said separator for further promotion of flow in the system. g

9. In a steam system, a combination as set forth in claim 8, in which said thermostat is in heatexchange relation with the fluid discharge from said valve for rise in temperature by heat supplied by said return line.

10. In a steam system, a combination as set forth in claim 9, in which said thermostat is in a passage to receive the discharge from said valve, said passage having restricted outlet capacity to cause the pressure therein to rise when said valve is open, and in which said thermostat is in said passage.

11. In a steam system, a combinationas set forth in claim 9, which includes means to cool the interior of said separator with boiler feedwater to further promote flow in the steam system.

l2. In a steam system having a boiler, at least one steam-using device, and a return line, said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of: a valve to release fluid from said return line to promote flow in the system, a thermostat operatively connected to said valve ,for openingr action of the valve in response to temperature above a given level and closing action in lresponse to temperature below said level, said thermostat being in heat-exchange relation with fluid in said return line upstream from said valve,

lsaid temperature level being below the tempera- -for opening action of the valve in response to temperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with fluid in said return line upstream from said valve, said temperature level being below the temperature of said steam supply, a boiler feed line under pressure higher than the pressure in said return line, and a pump having its intake side connected with said return line to continually remove condensate therefrom for further promotion of dow in the system, said pump having its discharge side connected with said boiler feed line.

14. In a steam system having a boiler, at least one steam-using device, and a return line, said device and return line forming a. clear channel from said boiler for iiowdpromoting pressure communication through the system, the combination therewith of a heat exchanger included in said return line having a passage for heating water, a valve to release fluid from said return line to promote flow in the system, a thermostat operatively connected with said valve for opening action of the valve in response to temperatures above a given level and closing action in response to temperatures below said level, said level being lower than the temperature of the steamsupply, said thermostat being positioned to be heated by uid in the return line upstreamvfrom said heat exchanger, and means to remove condensate from said return line at a rate to prevent accumulation of condensate at said thermostat.

l5. In a steam system, a combination as set forth in claim 14, in which said thermostat is positioned inside said heat exchanger. 1 I

16. In a steam system, a combination as se forth in claim 14, in which said valve is downstream from said heat exchanger and said thermostat is positioned between the heat exchanger and the valve. y

17. In a steam system having a boiler, at leas one steam-using device, and a return line. said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of: a separator included 'in said, return line, a valve to release .fluid vfrom said separator to promote flow in the system, a thermostat operatively connected to said valve' for opening action of the valve in response to temperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with returns from the system upstream from said valve, said .temperature levelbeing below the temperature of said steam supply, and means to remove condensate from said separator at a rate to prevent accumulation of condensate at said thermostat.

18. In a steam system, acombination as set forth in claim 17, in which said separator has means for circulating a cooling fluid therethrough to cause condensation therein. ,x

- 19. In a steam system havinga boiler, at least one steam-using device, and a return line, said device and return line forming a clear channel from said boiler for flow-promoting pressure communication through the system, the combination therewith of: a water storage tank, means including a valve to 'release fluid from said return line to heat water for said storage tank and to promote flow in the system, .a thermostat operatively connected to said valvefor opening action of the valve in response to temperature above a given level and closing action in response to temperature below said level, said thermostat being in heat-exchange relation with returns from the system upstream from said valve, said temperature level being below the temperature of said steam supply, a boiler feed line under pressure higher than the pressure in said return line, a pump having its intake side connected with said return line to continually remove condensate therefrom for further promotion of flow in the system, said pump having its discharge side con- '1| nected with said boiler feed line, a. heat exchanger included in said return line having a water-heating passage connected with said boiler feed line,

and means including a second pump to forcevwater from said tank through said passage into said v 'flow in the system.

20. In a steam system, a combination as set forth in claim 19, including means to supply new water to said storage tank and a second valve to release steam from said return line automatically when said supply means operates.

21. A steam-heating system having a plurality of steam-using devices with a steam supply and a return line closed to the outer atmosphere and connecting the devices with the supply for return of steam thereto valve means to release fluid from said return line to maintain iiow in the system,

l and a thermostat operatively connected with said valve for opening action of the valve in response to temperatures in said return line above a given temperature and for closing action oi the valve in response to temperatures below the given tem-- perature, said given temperature being lower than the prevailing temperature on the supply side oi.'

the system.

. ORVILLE A. HUNT.

LOUIN TILLER.

REFERENCES @REED The following references are of record in the ille of this patent:

UNITED STATES PATENTS Number Name Date y2,366,332 Harrison et al l an. 2, 1945 

